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Coalpro, the trade association for UK coal producers, has produced a comprehensive guidance document on traffic management in quarries. View it at: http://www.coalpro.co.uk/docs/CoalPro%20Traffic%20Management_A.pdf
QNJAC recognises that this guidance is aimed at the opencast coal industry. However, the principles it contains are applicable to any size and type of quarrying operation. The photographs in the document are inevitably of large mining plant and equipment and this must be borne in mind. This information sheet has been developed by Coalpro and endorsed by QNJAC to help quarry operators, contractors, managers and others make health and safety improvements in the quarry industry. This guidance represents good practice which may go further than the minimum you need to do to comply with the law.
REMEMBER
Quarry vehicles have been involved in numerous incidents
The Confederation of UK Coal Producers (CoalPro) is the trade organisation representing most of the deep and surface coal producers. Production of coal in the UK is by far the most efficient in Europe. The coal industry employs over 9,000 people directly and many more in related activities (supplies, plant maintenance, services etc). The members of CoalPro are clear in their responsibilities to both the industry and the community at large. To ensure that these responsibilities are met, CoalPro members: Will seek too: Continue their valuable contribution to UK energy requirements through the production of secure and competitively priced coal. Develop viable and well managed businesses to benefit employees and share holders with the promotion of the highest operating and environmental standards. Will commit to: Promote training, health, safety and research and development of all aspects of the business. Areas will include, amongst other matters energy efficiency, clean burn technology, environmental standards and restoration techniques. Promote the highest practicable standards of operation to lessen the impact on the environment and amenities, including liaison with local community groups. Adhere to full statutory environmental controls and support the continued development and reinforcement of such controls. Adopt an environment code which will be regularly reviewed and updated.
Issue 1.0 of the Guidelines for Surface Mining Traffic Management reflects our commitment to keeping CoalPro members and the industry up to date with Health and Safety developments, new legislation, guidance and best practice. The Guidelines are intended for information, general guidance and as an aide-memoir for senior and operational managers within the industry. Minor changes and revised guidance will be published as required in the future and as such we welcome and encourage any comments on this Guidance. We acknowledge that improvements can always be made, and whilst the Guidelines do not constitute advice, or indicate any specific course of action.
Acknowledgements CoalPro acknowledges the time, effort, experience and expertise of all those who contributed to this document. Particular mention must go to: Jason Davies Miller Argent Keith Dunbar UK Coal Jeff Fowler Banks Group Philip Jarman Celtic Energy David Patterson Scottish Resource Group
Disclaimer The contents of this document are intended for information and general guidance only. Detailed professional advice should be obtained before taking or refraining any action in relation to the contents of this guidance document.
Contents
Introduction Legal Duties Responsibilities Safe driving and plant operation Plant Operators and Drivers Competence and Capability Training and Authorisation Safe Workplaces Site Design/Pre Planning Design Traffic Management Plan Site Access and Parking Areas Contractors and Visiting Drivers Design and Layout of Road Systems Site Roads Benches and Haul Roads Gradient & Cross Slope Rock Traps Alignment Edge Protection on Roads Maintenance and repair Drainage Pedestrian Segregation Supervision of Traffic Movements Speed Limits Traffic Signage Lighting Control and Supervision Traffic Controller Radio Control Mobile Phones Newspapers, magazines and other such reading materials Vehicle Operating Practices Vehicle Start Up Driving a Vehicle Entry into a Loading Zone Loading Operations Tipping Operations Manoeuvring Vehicles in Restricted Areas Overtaking Parking Dust Suppression Fuelling and Servicing General Wheeled Mobile Plant Safe Vehicles Vehicle Selection Definition of Heavy / Light Vehicles Vehicle Inspection and maintenance Vehicles and Visibility Seat Belts Roll Over Protective Structure (ROPS) Falling Objects Protection (FOPS) Brake Testing Breakdown and Recovery References Tracked Mobile Plant External Haulage Deliveries
Introduction
CoalPro is committed to promoting the best working practices to ensure the health, safety and welfare of all employees and contractors throughout the coal industry in the UK. Every year, a significant number of people are killed by accidents involving vehicles in the general workplace, and many more people are injured. Workplace incidents also result in consequential damage and costs to the business. Guidance is available from the HSE and other industry bodies covering general workplaces but Surface Mining is a specialist activity involving some of the largest items of plant in the UK. This Traffic Management Guidance has been produced by CoalPro to help those involved in surface mining operations to control the risk of accidents involving plant and ancillary vehicles. It is designed to identify some of the safety problems for common vehicle operations on site. Better planning, training and awareness, and the appropriate use of vehicles, can avoid most of these incidents. It is not envisaged that this guidance will cover all traffic management issues on a site and companies should complete their own risk assessment and take competent advice when implementing traffic management systems. CoalPro RIDDOR reportable injuries were reviewed over the period April 2004 to the end of March 2011. Of the 306 reportable injuries some 25% (75) related to transport and mobile plant incidents.
Legal Duties Health and Safety law requires that risks at work are controlled as far as is reasonably practicable. For a control to be reasonably practicable, the cost must be sensible in proportion to the safety gain (reasonable) and it must be physically possible (practicable). Ultimately, only a court can decide whether what you did was reasonably practicable. It should also be recognised that some legislation is absolute and is not qualified by so far as is reasonably practicable. The main pieces of legislation that have been referred to for this CoalPro Guidance are: The Quarry Regulations 1999 Provision and Use of Work Equipment Regulations (PUWER) 1998 Management of Health and Safety at Work Regulations 1999 Workplace (Health, Safety and Welfare) Regulations 1992 The Workplace (Health, Safety and Welfare) Regulations 1992 the Quarries Regulations
1999 place various duties on employers and those in control of workplaces, including the organisation of traffic routes. The first step in preventing transport accidents is to carry a comprehensive risk assessment of all activities involving vehicles. Site vehicles and traffic account for many significant hazards in a surface mine. These hazards must be assessed to ascertain who is exposed to these hazards, whether existing controls are adequate or can be improved. There are 5 simple steps to follow when carrying out risk assessment of transport hazards at work: Identify the risks posed by transport activities Identify who might be harmed Evaluate the risks Record the assessment Review and update the assessment regularly or when a change or incident takes place.
Responsibilities It is the responsibility of the Quarry Operator to ensure that procedures are in place which cover all aspects of the management and control of traffic within the quarry and that all persons are given relevant information and instruction on the hazards and control measures associated with traffic management, and thereby eliminate the risk of fatalities, injuries and incidents arising from the operation of mobile plant, ancillary vehicles and other general transport. The Quarry Operator should ensure that all mobile plant and ancillary vehicles used on quarries are safe and suitable for use under the working conditions in which they are employed. All mobile plant and ancillary vehicles should comply with any relevant statutory requirements and should be properly operated and maintained in accordance with the manufacturers operating recommendations and all relevant Quarry Operators requirements. The Quarry Operator should undertake a risk assessment identifying the hazards associated with traffic within that workplace. From that risk assessment traffic management rules, including the vehicle rules as required by the Quarries Regulations 1999 should be developed. Management, employees and safety representatives should be involved in undertaking this risk assessment. The risk assessment and Traffic Management Rules should be monitored and reviewed on a regular basis.
Safe Workplaces
Site Design/Pre Planning Design
The initial design and planning of any workplace, in consultation with all relevant bodies is vitally important to all future operations. Discussions should involve relevant internal/external planning, technical specialists and internal operational staff. Your health and safety team should play an important part during this consultation. This consultation should take place prior to submission of planning permissions to ensure that a well thought out feasible submission is presented to the relevant local authority. Particular attention should be paid to the following site areas: Access to the site and security controls. Traffic routes, parking areas, delivery points Distribution Point Coal Processing areas Weighbridge location Sheeting and Tipping areas Site offices and amenity areas Workshop layouts and designs Environmental control issues and requirements. Operational Designs for Haul Roads Plant Parking areas Tips and Excavations Lagoon Systems Coal Stocking, Sheeting Areas, Tip Stand offs Utilities Water ways Transport infrastructure Public roads and footpaths
Safe Workplaces
change as the site work progresses. There will be pedestrian traffic, employees, contractors and visitors either on their way to or from their normal place of work at the beginning or end of the working day, or as part of their work during the day. Traffic routes should be planned to give the safest route between places where plant, vehicles and pedestrians have to call, park or operate. Pedestrian routes should be planned to minimize exposure of the pedestrians to vehicle movements by the installation of barriers, crossing points etc.
Site Roads
Roads should be adequately constructed and be suitable for the vehicles using them. Roads should be surfaced with suitable materials i.e. rock-fill. They need to be well drained to prevent a slippery road surface and protected from falling rock with the installation of suitable rock traps where applicable. Road widths should be sufficient to allow two of the largest vehicles using the haul road to pass safely. Each lane of travel should provide clearance, left and right of the widest vehicle in use, which is equivalent to one-half the vehicle width. Separate roads should be provided for ancillary vehicles where possible. The design of traffic routes should take into account the type and size of plant and vehicles being operated on the site and the plant should be designated as heavy plant or as light vehicles i.e. ancillary vehicles. Traffic route design should include the segregation of the heavy plant and the ancillary vehicles. Separate roads should be provided for ancillary vehicles around areas such as workshops and for access to the operational areas of the site so far as is reasonably practicable. Separate traffic controls and signage should be established for the safe passage of ancillary vehicles on these routes. Recommended minimum road width:
Roads should not be designed at more than 10% gradient. Cross slope, the difference in elevation between the road edges, must be given consideration during haulage road design and construction. On straight roads a level surface would be most beneficial. On curves a cross slope may be required to assist the driver in manoeuvring his vehicle through the curve. Adverse cambers should be avoided. Adequate water drainage may also require that a cross slope be created. To accommodate both drainage and steer-ability, balance must be established between a level and sloped configuration. The rate of cross slope that will allow a rapid removal of surface water without adversely affecting vehicular control must be determined.
Rock Traps
If roads are in use along the bottom of a face or below a tipping area the required widths should always be considered to ensure that any vehicles using this road are a suitable distance from the face to protect them from potential rock falls. Consideration should also be given to the installation of rock traps to catch any falling materials. They may need to be designed by the Geotechnical Specialist.
Safe Workplaces
Alignment
Benches and roads should be designed with viewing distances and alignment in mind to ensure that a vehicle rounding a curve, cresting a hill, descending a grade, or approaching a junction can stop in time to avoid an object in the road or a vehicle pulling onto the road.
Drainage
Roads have to be adequately constructed to be suitable for the vehicle using them. This means they need to be well drained and surfaced with suitable materials. This not only improves safety but also productivity. Wherever gaps are left in road edge protection these must be designed so as to prevent vehicles from leaving the roadway and the gap must be minimised to the narrowest practicable.
Pedestrian Segregation
The greatest risk to pedestrians is from vehicles and mobile plant. Pedestrian activity within the operational areas shall wherever possible be restricted, particularly in hours of darkness. For certain operations no entry zones should be identified and clearly marked by signs, fencing, cones etc. Employees must not enter operational areas as a pedestrian unless authorised to do so. Where practicable, pedestrian routes or zones should be established and designated with suitable signs, barriers, road markings etc. particularly where plant is operating or manoeuvring. Such areas would be in plant and vehicle parking areas, around static plant and around buildings particularly workshops. The Traffic Management plan should also consider pedestrian activities.
Speed Limits
Plant and vehicles must be operated and driven safely at a speed which is consistent with the prevailing site conditions. Site conditions can vary considerably over a relatively short period of time, either because of changing weather conditions reducing visibility or by road conditions deteriorating; reducing traction or becoming more slippery or because of the volume of traffic which accelerates wear and tear on bends and other areas where braking takes place. There is no hard and fast requirement for speed limits on haul roads, as the surface mine environment is very dynamic and subject to the above changing conditions, however consideration should be given to maximum speed limits. Any such speed limits would need to be regularly monitored and reviewed to ensure that they are still appropriate. Permanent site roads such as access roads to the office, welfare buildings, workshops, stocking ground, weighbridge etc. should be assessed for suitable speed limits, as invariably these are metalled roads and speeding vehicles can be a problem. Where speed limits are set adequate signage must be in place.
Traffic Signage
Potential dangers need to be indicated by suitable warning signs. Drivers and pedestrians should be able to expect that the layout, signs, road furniture and markings on site will be similar to those on public roads. Signs and lighting should be kept clean and well maintained so that they are always visible. Signs that should be considered for use along surface mine haul roads include: To identify separate traffic routes and inform who can travel them To identify safe waiting (holding) areas for working and operational areas To identify hazards such as heavy plant crossing points, overhead obstructions etc. To identify traffic controls such as speed limits etc. To identify pedestrian routes and crossing points. Entry to workshop, maintenance, processing etc areas
Lighting
The Quarries Regulations 1999 Regulation 23 and guidance requires that there should be adequate lighting of site locations and vehicles at all times to enable all persons to work safely and in safety. Adequate lighting should be provided to all areas and especially to those areas used in hours of darkness or in poor visibility or diminished lighting conditions. As a minimum, lighting should be provided for junctions, around plant and buildings, pedestrian routes and areas where loading/unloading is to be carried out.
Safe Vehicles
Vehicle Selection
All mobile plant and ancillary vehicles used on sites shall be safe and suitable for use under the working conditions in which they will be employed. All mobile plant and vehicles shall comply with any relevant statutory requirements and shall be properly operated and maintained in accordance with the manufacturers operating recommendations and all relevant company requirements.
Some plant or vehicles may need to be re-classified according to their size and the operations that they perform i.e. small front loading dump trucks, mini-excavators etc Other plant or vehicles not listed above shall be identified and classified according to their size and the operations they perform on site. The classification of each item of mobile plant or vehicle on site shall be specified in the Site Vehicle Rules.
Safe Vehicles
found and remedial action taken. Instructions to drivers concerning plant and vehicle checks and the reporting of defects shall be specified in the Site Vehicle Rules. Inspections should be carried out on the machine and it should be suitably recorded in a vehicle log book or checklist. The checks should include items subject to damage or wear, fluid levels, safety devices and the defects recorded and reported. Safety critical defects must be reported immediately to the appropriate Supervisor or Manager to determine the serviceability of the machine.
Seat Restraints
Site vehicles and mobile plant have many safety features; few are as easy, as basic or as important as seat belts. A Seat belt is designed to secure the occupant of a vehicle against harmful movement that may result from a collision, roll-over or a sudden stop. Using seat belts in our personal vehicles has become second nature as it is mandatory (it is the law) to wear them on the public highway. When it comes to site vehicles and mobile plant, seat belt use should also be second nature. The Site Vehicle Rules should specify that seat belts, where fitted, must be worn whenever the operator is seated in the cab.
Brake Testing
The Quarries Regulations 1999 and Approved Codes of Practice and Guidance, require the operator to make Vehicle Rules that include cross-references to the scheme for inspection and maintenance of plant. The Guidance, Appendix 4, paragraph 14, requires that a suitable inspection scheme be in place to ensure vehicle brakes are kept in good condition at all times. In practice, a typical service brake test regime would consist of: a simple driver stopping / instrumented test, or stall test. Carried out either per shift or daily; and an instrumented test at an interval of between 1 and 3 months carried out by a competent person.
Safe Vehicles
The document, Guidance on Brake Testing for Rubber-tyred Vehicles, Operating in Quarries, Opencast Coal Sites and Mines, prepared by QNJAC and published by EPIC (now MPQC) and OPERC, explains the brake ratio method of brake testing and gives a step-by-step guide on how to correlate braking performance with actual site conditions and how to design and put in place a suitable brake test regime.
Safety Passport or be able to demonstrate a similar level of competence. All contractors employees should be able to demonstrate their individual level of competence. This may be a letter of competence from their employer advising how this competence was achieved.
c) They monitor through regular visual inspections from a safe vantage point that site vehicle operations are being carried out in compliance with these rules. d) That one way systems and segregated routes are used and reversing movements are minimised. e) Access to any haul roads or ramps not suitable for use is restricted by placing a physical barrier at the entrance to the restricted area. f) Haul roads and ramps are suitably constructed avoiding steep gradients, sharp bends or blind dips wherever possible. g) Adequate edge protection is provided on haul roads, tip edges, water bodies and other locations where there is a drop edge or other hazard. h) Roads are adequately maintained with re-grading, slurry and debris removal and dust suppression etc. as necessary.
i)
Unforeseen incidents such vehicle breakdowns, bogged vehicles, rock falls, subsidence etc. are promptly dealt with, with a suitable risk assessment and remedial action. All site visitors or sub contractors with vehicles will be assigned to the control of a Supervisor or authorised person and be escorted to and from their place of work. A hand held radio must be provided and appropriate instructions issued.
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k) Appropriate corrective action is taken to address any breaches of these rules, reporting non-compliances to the Site Manager as appropriate. l) During periods of dry, windy weather, water shall be evenly applied at regular intervals to the surface of the haul roads and benches so as to suppress dust and prevent it from becoming airborne and causing a visibility nuisance. The quantity and frequency of water application must not create a soft slippery surface, particularly on slopes and bends.
m) In adverse weather conditions supervisors must ensure that plant operators drive to the prevailing conditions. An assessment must be made of deteriorating conditions to establish if operations can continue safely or if vehicle movements must be suspended. Examples of deteriorating conditions could be rain, ice, snow, fog etc n) They monitor through regular visual inspections from a safe vantage point that site vehicle operations are being carried out in compliance with these rules. o) Wherever possible one way systems are used and reversing movements are minimised. p) Access to any haul roads or ramps not suitable for use is restricted by placing a physical barrier at the entrance to the restricted area. q) Haul roads and ramps are suitably constructed avoiding steep gradients, sharp bends or blind dips wherever possible. r) Adequate edge protection is provided on haul roads, tip edge, water bodies and other locations where there is a drop edge or other hazard. s) All site visitors or sub-contractors with vehicles should be assigned to the control of a Supervisor or authorised person and be escorted to and from their place of work. A hand held radio should be provided and appropriate instructions issued. t) Any safety concerns are reported immediately to the Site Manager as appropriate and the necessary remedial action taken.
Radio Control
Radios should be used as a communication aid where appropriate but should not be regarded as the primary means of communication. Eye to eye contact between drivers and/or pedestrians and effective hand signals remain the primary means of communication and should be used wherever possible. You should not rely solely on a radio to keep you safe. All radio communication should be acknowledged before carrying out the instruction, requirement or request. When on site you should have a radio in your possession or be accompanied at all times by a person carrying a radio, except in areas exempt from the use of radios, if identified as such by the Site Manager. If you have been issued with a site radio you should use it in accordance with the Site Managers instructions. Formal protocols should be drawn up and operators trained in their use. Site Supervisors should monitor radio communication at all times and take appropriate action to ensure that instructions are properly communicated and understood. Radios should be used to communicate for operational purposes only. Communication by radio should be carried out from a place of safety at all times. Where more than one vehicle is involved, radio instructions should be given in an order that will ensure safe vehicle movements. Site radios may be either a fixed vehicle unit or a portable handset. Sufficient numbers of portable handsets and charged spare batteries for handsets should be maintained at all times. These should be returned to the charging unit after use to ensure that a sufficient number of working radios are available for operational purposes. Users should ensure that radios are treated with care and kept in good order. Radio faults should be reported to a Supervisor and a replacement requested. Local rules should be in place to cover radio faults. Site radios should be switched on at all times and tuned to the channel for site communications. Other channels should be used for specific works or emergencies as appropriate.
Abuse or frivolous use of the site radio system should not be tolerated and anyone guilty of this should be subject to disciplinary action. The provision of Caller ID would alleviate most mis-use. Radios should only be used when it is safe to do so and not when carrying out a complex vehicle movement or other task where the use of a radio might present a risk to health and safety e.g. a reversing manoeuvre. It is essential that radio users identify themselves and name the driver of the vehicle or personnel they wish to communicate with. Vehicle operators should not interrupt another persons communication except in an emergency. Emergency procedures should include the use of radios and emergency call signs.
especially to the front or rear of the vehicle. In the case of rotating, tracked or articulating vehicles this is particularly important.
Driving a Vehicle When driving a vehicle in the site the following points should be considered when preparing vehicle rules. a) All vehicles driven within the site should use dipped headlights at all times. b) Ensure that the area around the vehicle is clear before moving away or altering direction. Where reasonably practicable, large vehicles must never be turned using full steering lock from a parked position. Any area where the vehicle may manoeuvre must first be checked and must be clear. Where necessary the driver must exit the cab to check that the area is clear before moving off. c) Drive with due care and attention and at a speed that is appropriate to the prevailing ground, weather and visibility conditions. Obey local speed limits where applicable. d) A safe distance must be maintained from the vehicle in front so that emergency action can be taken. As a practical rule, vehicles must maintain a minimum of 3 large truck lengths (approx. 30 metres) away from the vehicle in front and further in poor conditions. Particular care should be taken on haul roads that have been newly sprayed with water for dust suppression purposes. e) Vehicles will normally be driven on the left-hand side of the road unless specific instructions are issued or local rules implemented to the contrary. f) Loaded vehicles always have priority over empty vehicles. g) Light vehicles must always give way to heavy vehicles and not enter heavy vehicle areas without permission from supervisors. A safe distance must always be kept from heavy vehicles. h) Light vehicles should not travel along areas of reduced visibility on the off sides of dump trucks without advance communication with the dump truck operator. i) When vehicles of similar size and capacity are sharing a haul road and there is a need to give way, the vehicle travelling uphill has priority. Vehicle operators must give way to traffic coming from the right at junctions.
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k) Only trucks for loading or tipping purposes may enter the swing radius of an excavator or manoeuvring zone of a dozer or loading shovel. Pedestrians and other vehicles must not enter the area unless granted permission by the Supervisor or other designated person and the plant is stationary with the bucket, blade, ripper or other raised equipment grounded.
m) On no account should a vehicle be driven within any cordoned off areas. n) With the exception of authorised vehicles that have been fitted with suitable safety devices, road going vehicles must be escorted while being driven within the quarry working area. o) Coasting out of gear is forbidden in all circumstances. p) Overtaking manoeuvres must only be done when safe to do so and with the full acknowledgement of the operators in front and to the rear. Signals, radio communication and visual contact must be used as appropriate. Overtaking must not be attempted where there is not enough road width to do so safely or on a short road, ramp or blind corner or in wet and slippery or poor visibility conditions. q) Vehicle operators must keep their cabs clean and tidy, store loose and personal items securely and ensure there are no obstructions to visibility aids, windows, controls, gauges, warning lights etc. Vehicles will be driven with the doors closed at all times. r) Vehicle operators must remain alert at all times to pedestrian activities which will be kept to a minimum in the quarry. Operators who are unsure about the location of a pedestrian or light vehicle should stop their vehicle immediately. Particular care should be taken during reversing manoeuvres and at maintenance and parking areas. s) Vehicles must never enter a pedestrian only zone. Pedestrians must never enter a No Pedestrian Area. t) Pedestrian activities must be kept to a minimum and vehicle operators must remain in their cabs wherever possible. When leaving the cab of a vehicle at any time a vehicle operator becomes a pedestrian and will be required to wear a hard hat, high visibility waistcoat/jacket and safety boots. u) Pedestrians must remain in full view of vehicle operators and must communicate with vehicle operators to confirm their presence. Always check never assume that you have been seen. v) Vehicle operators must immediately contact a site supervisor in the event of any breakdowns, emergencies or any other unplanned event. w) In the event of an accident mobile plant should not be moved and operators should remain in their cabs unless there is imminent danger. Mobile Plant will only be permitted to be moved once a thorough investigation has been carried out.
x) If mobile plant is obstructed such that the obstruction is large enough to offer resistance to forward or reverse movement then the machine should be halted immediately and the obstruction investigated before plant damage occurs or is made worse.
Entry into a Loading Zone The loading zone is defined by the manoeuvring zone of the excavator or loading shovel and the manoeuvring zone of the trucks being loaded or waiting to be loaded. a) The entry of any vehicle other than a dump truck into the loading zone of an excavator or loading shovel is prohibited while excavation and loading operations are active. b) The operators of dozers, graders or rigid water bowsers and other heavy plant that are required to enter the loading zone for operational purposes must receive permission from the Supervisor or other designated person who will exercise control of traffic movements to ensure that no collisions can occur and will give appropriate instruction to vehicle operators. c) If light vehicles or pedestrian are required to enter the loading zone, contact must be made with the Supervisor or other designated person by radio to request permission to proceed. Before granting permission the Supervisor or other designated person must ensure that the excavator or loading shovel is stationary with the bucket grounded and dump trucks and other heavy plant have been parked up in a safe location in accordance with Supervisors or other designated persons instructions. d) In each situation the Supervisor or other designated person must ensure that radio contact is made with the appropriate personnel and must not authorise entry of vehicles and pedestrians into the loading zone until he has ensured all dump trucks and heavy plant have parked up in a safe location. e) If at any time a vehicle or pedestrian enters the loading zone without prior permission a Supervisor or other designated person must be notified immediately and all plant must stop and remain stationary until instructed otherwise by a Supervisor or other designated person. The operator of the excavator or loading shovel must ground the bucket and ensure that the excavator or loading shovel does not move. f) If at any time a vehicle or pedestrian enters the loading zone without permission and is seen by any driver, that driver must immediately stop, notify the supervisor and ensure using his radio that all other machines in the loading zone are told to stop and remain stationary. The operator of the excavator or loading shovel must ground the bucket and ensure that the excavator or loading shovel does not move. The supervisor or other designated person must then take control of the situation before any vehicle is allowed to move. g) For further guidance refer to the flow chart Operational Control of Vehicle Movements in Active Heavy Plant Areas
Tipping Operations a) Suitable edge protection berms with a minimum height equal to 1.5m or the radius of the largest vehicle wheel, whichever is greater, must be maintained at drop edges. Such berms and stand-offs should be designed or considered by the Geotechnical Specialist to ensure stability and allow for the maximum rear axle weights and dynamic loading. Tip edge berms must be maintained at all times to a suitable profile as illustrated below.
b) Dozers and other vehicles in the tipping area must remain in the view of the operator of a reversing vehicle at all times i.e. on the cab side. Dozers and dump trucks must remain at least one truck width apart from other vehicles while on tip edges. Dump truck operators must never drive within the reversing path of a dozer. c) On no account should a vehicle be reversed blindly in a tipping area. Operators must make full use of visibility aids and should not reverse until they are certain that the path is clear and only if a stand-off or protection is in place adjacent to any edge or hazard.
Where possible the dozer should work with a tipped load between the dump truck to ensure a physical control measure is in place to maintain a safe distance. Do not enter the dozers reversing path.
d) On no account should a dozer operator leave a tip edge unless a suitable edge protection berm is in place. e) If due to a breakdown or other unforeseen circumstances the dozer operator is unable to form a suitable edge protection berm, the operator must inform a supervisor immediately. f) Dump truck operators must ensure that an orderly sequence of tipping is followed at all times giving due attention to other vehicles in the tipping area. g) On approach to the tipping area the dump truck must be positioned so that it can reverse safely taking account of other vehicles in the vicinity. h) Dump trucks must be reversed safely in the tipping area and approach the tip edge at a decreasing speed. The dump truck must be manoeuvred to allow it to stop at right angles adjacent to the tip edge berm.
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k) On no account should a vehicle be allowed to mount a tip edge berm or the load tipped directly over the tip ed
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3
OK
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Manoeuvring Vehicles in Restricted Areas Where vehicle size segregation is not possible then restricted areas shall be established for working areas. Working areas may be defined as: Any area where multiple mobile plant operates. The movement of all mobile plant must stop before ancillary vehicles or pedestrians enter the working area. Site Traffic Management Rules shall specify the working areas. The position of working areas may continually change due to site operations, however as a minimum, the following must be specified as working areas.
A place where multiple items of mobile plant are operating:a) Operating area around an excavator on mining operations and the traffic movement associated with it. b) Operating area around a dozer on a tip and the traffic movement associated with it. c) Operating area around a loading shovel(s) at stockpiles, processing and loading areas and the traffic movement associated with it.
Restricted Area
Operational area An area outside a restricted area where mobile plant and ancillary vehicles operate.
Some restricted areas and operational areas may intersect or overlap. Under these circumstances the whole area will be classified as a Restricted area. Site Traffic Management Rules will specify:a) The extent of the exclusion zones for restricted areas. b) The procedure for entering restricted areas and operational areas. Safe waiting areas (Holding Areas) should be provided outside exclusion zones to enable ancillary vehicles to park, or pedestrians to wait, in a safe place until authorised to enter the exclusion zone when traffic movement has been stopped. a) Site workshops and a 10 metre radius around vehicles and plant parked for servicing and maintenance will be classified as restricted areas in which vehicle movements should be strictly controlled. Other restricted areas at sites will be identified by management on a risk assessment basis. b) Vehicles should not enter or leave a restricted area, where other vehicles or
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Overtaking a) Where practicable, traffic segregation should be provided to minimise the requirement for utility vehicles, land rovers etc. to overtake larger vehicles. b) Where utility traffic routes are provided, then overtaking can be controlled by the provision of single traffic routes with overtaking bays, so that the one vehicle is stationary whilst being overtaken.
c) On the main haul roads overtaking should be subject to an approved scheme for overtaking or undertaking. d) Consideration should be given to utility vehicles not overtaking dump trucks or water bowsers when they are in operation. e) In general, no overtaking should take place on road junctions or on bends.
Parking a) Vehicles should be parked on level ground wherever possible to minimise the possibility of them being set in motion. b) Vehicles should be parked in an authorised parking area in accordance with a parking
system approved by the Site Manager. If it is not possible to do so or if a vehicle is broken down, permission must be sought from a supervisor to park elsewhere. c) When leaving a vehicle unattended the engine should be switched off, ignition key removed, all brakes applied and the appropriate gear selected to suit any gradient. The key or any other device for starting vehicles must be kept in a secure place to prevent unauthorised starting of vehicles. d) Vehicles and equipment should be parked a suitable safe distance from a quarry face to minimise the risk of being struck by falls of ground. When this is unavoidable due to a breakdown or unforeseen circumstances a risk assessment must be carried out by a manager or supervisor before permission is given for personnel to enter the area. e) Ground engaging equipment i.e. excavator buckets, dozer blades, ripper teeth and scraper bowls should be lowered to the ground when parking and if stopping to be serviced or fuelled. f) Vehicles should never be parked within the swing radius of an excavator or the
Dust Suppression The watering of haul roads to suppress dust has the potential for traffic accidents; either by the water bowser turning over or by the haul roads becoming very slippery because of wet bends and ramps and any other sections of haul road where brakes may be applied. Drivers of water bowsers should take extra care, especially when full, to avoid driving across gradients due to the potential increase in instability of trucks carrying fluids. Water bowser operators should at all times patch spray haul roads and avoid blanket spray or excessive amounts of water being deposited on the roads (especially in braking areas, gradients and junctions of haul roads).
c) Fuelling and servicing of loaded quarry vehicles is strictly prohibited. Where this is un avoidable due to unforeseen circumstances e.g. a breakdown, a risk assessment should be carried out by a manager or supervisor and appropriate control measures implemented before the fuelling or servicing operation is allowed to commence. d) Quarry vehicles should be fuelled and serviced in areas designated for this purpose by site management and in accordance with the authorised fuelling and servicing procedure. Fuelling and servicing should not take place adjacent to faces or high walls. e) There should be effective communication between personnel at all times using visual contact, recognised hand signals and verbal contact using radios as appropriate. The fuel attendant/serviceman should control the fuelling/servicing operation and vehicle operators must act upon any instructions received. Wheeled Mobile Plant a) Fuelling and servicing of mobile plant should take place in designated areas in accordance with a written procedure approved by the Site Manager which must identify designated areas, parking and immobilisation procedures. An area of level ground should be selected in a safe position away from normal site traffic. b) Maintenance personnel intending to work on vehicles during service intervals or break times should always ensure that vehicles are immobilised before approaching. Immobilisation procedures must be followed. c) Operators of vehicles being serviced should not re-start their engines or move away until signaled to do so by the fuel bowser operator or servicemen who must remain in a safe position in full view of any vehicle operator. d) Operators of vehicles being serviced in areas other than designated parking areas should move away in a forward direction wherever possible and should only reverse if permitted by a written safe system of fuelling or servicing or under the guidance of a Supervisor or other designated person. Tracked Mobile Plant a) Tracked excavators, dozers, loading shovels and drill rigs should be positioned in a level area of a sufficient size that permits safe access for the fuel bowser and service vehicles. b) Excavator buckets, dozer blades and rippers should be lowered to the ground before fuelling or servicing commences. Where fitted isolators/immobilisation switches must be used. c) There should be clear communication between machine operators and the fuel bowser operator and servicemen before and during fuelling or servicing. d) The operator of a service vehicle who has the permission of a Supervisor or other designated person to enter an area where fuelling or servicing of a machine is underway should approach with caution, stop a safe distance away and communicate with other personnel before entering the area.
j)
External Haulage
a) External coal haulage vehicle operators should comply with any site specific rules applicable. b) External coal haulage vehicle operators should not be allowed to proceed into the working area until they have received appropriate permission and instruction in any relevant local rules. Site Managers will ensure that local procedures are implemented to ensure that drivers are made aware of site rules. c) The local rules and site traffic management plan will outline procedures and designate loading and unloading areas, trimming off areas, tipping areas, sheeting areas, tailgate securing areas and safe places for vehicle inspections. d) Operators of external coal haulage vehicles should remain in the cab during loading operations and at all other times within the loading area. If for whatever reason a driver of an external haulage wagon leaves the cab the loading shovel operator should place the bucket on the ground and ensure the shovel remains stationary until the wagon driver returns to a safe place/cab. e) Drivers should ensure that their load is fully discharged. Tipping bodies must be lowered as soon as possible after tipping to prevent the risk of overturning. f) Site traffic management plans will specify areas where coal haulage drivers are
permitted to get out of their vehicle. No pedestrians are permitted within 30 metres of an operational loading shovel unless there is a suitable physical barrier to protect the pedestrian from vehicle movements. g) Coal haulage drivers should ensure that all lights, directional indicators and reverse warning indicators are working at all times when on site. h) In the event of a breakdown or an emergency involving a coal haulage vehicle the driver should remain in his cab unless it is not safe to do so and follow the local procedures for stranded vehicles by contacting a supervisor or weighbridge operator in the first instance. The use of mobile phones will only be permitted in an emergency.
Deliveries
All delivery vehicles should report to a designated control point to sign in, to receive site rules and site induction as necessary and to receive instructions regarding points of delivery and who to report to. The site rules should include traffic routes to be taken, parking arrangements, pedestrian control and the need to observe signs and instructions in relation to traffic control and segregation, where applicable. At the point of delivery the receipt of the goods will be controlled by a designated person who will ensure that parking and unloading rules are observed. Site specific rules should be prepared to cover the delivery of gas oil, explosives and other hazardous materials. After unloading the delivery vehicle should return to the designated control point to sign out. Plant delivered to site should be escorted to the designated off loading or build area away from other plant movements. The areas should be suitable for all relevant works such as cranes etc.
References
1. 2. 3. 4. 5. 6. The Health and Safety at Work etc. Act 1974. A Guide to the Health and Safety at Work etc. Act 1974. Management of Health and Safety at Work etc. Act 1974. Management of Health and Safety at Work Approved Code of Practice L21. Workplace (Health, Safety and Welfare) Regulations 1992. Workplace Health, Safety and Welfare Approved Code of Practice and Guidance on Regulations L24. Provision and Use of Work Equipment Regulations 1992. Work Equipment Guidance on Regulations L22. The Quarries Regulations 1999. Health and Safety at Quarries, The Quarries Regulations Approved Code of Practice L118. Traffic Signs Regulations and General Directions 1994. Signpost to the Health and Safety (Safety Signs and Signals) Regulations 1996 Workplace Transport Safety: An Employers Guide HSG 136. Supply of Machinery (Safety) (Amendment) Regulations 1994. Workplace Transport Safety: An Overview Leaflet INDG 199. Avoidance of Danger from Overhead Power lines General Guidance Note GS6. Guidance on Brake Testing for Rubber-tyred Vehicles operating in Quarries, Open Cast Coal Sites and Mines EPIC. Safe Use of Vehicles on Construction Sites HSG 144. Reversing Vehicles INDG 148 Safety in Working with Lift Trucks. Health and Safety in Road Haulage INDG 379 Mobile Plant Safety Standards Coalpro. Vehicle Safety Induction DVD Coalpro Fatal Accident Inquiry Determination 2011 FAI 32
7. 8. 9. 10.